How to manage different supply parameters for the same item based on demand quantity?

We are using unconstrained ASCP. We have some products that can be produced in a 'small' machine or can be produced in a large tank. If ASCP has created a planned order for a quantity less than 1000 it will be made on the small machine with the supply quantity = demand quantity. For example, we have a demand of 250, we will make exactly 250 on the small machine. But if the demand quantity is greater than 1000 we will make the supply in the tank with a fixed order quantity of 1590. Financially it will cost us less to do this and scrap the difference because the small machine is very expensive to run compared to the tank.
The challenge is, say we need 1200. ASCP generates a planned order for 1200 and all the dependent demands support 1200. Now we want to make 1590 and we are short of materials. This assumes we have set the item with no supply parameters. On the other hand, if we set a fixed order quantity of 1590 but only need 100 then we we have to scrap the materials for the balance due to a short shelf life.
Any ideas how to set a supply quantity using different parameters based on the demand quantity?
Mark Madal

Hi Mark,
I personally don’t see any standard solution for this requirement especially with an unconstrained plan.
However, if it is feasible, you can try below solution with a 'constrained plan with decision rules enabled' and check if it works,
1.   1. Define two different items – Item A and Item B
2.   2. Item A uses small machine in its routing and can have any demand that is below 999. So, Max order quantity = 999.
3.   3. Item B uses Large Tank in its routing and is a substitute of item A. Also, fixed order quantity = 1590.
4.   4. Define component substitution relationship between A and B. A and B will have identical BOM.
In a constrained plan with decision rules enabled, optimization logic will ensure that planned orders are generated for Item A whenever there is demand below 999. And for Item A, supply will always be equal to demand quantity. When the demand is more than 999, optimization engine will select substitute item B and will generated fixed supply of 1590 for it.
Check if this satisfies your requirement.
Regards,
Durgesh P
(Please mark this post helpful or correct, if answered)

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How to manage different supply parameters for the same item based on demand quantity?

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